Senior Design Engineer - Testing

Job Description SummaryActivities contributing to the design and development of products, solutions and systems. Includes activities linked to technical improvement of existing products and components Impacts approaches, projects and programs in the functional area or affected business organization and ways of working. Impacts quality, efficiency and effectiveness of own team. Has significant input into priorities. Guided by professional practices and policies that are shaped by the role. The role has moderate autonomy, requiring high levels of operational judgment.

Job Description

Roles and Responsibilities

• Lead the customer sponsored test programs in test rigs design, manufacturing, build, teardown & test operations. Act as a primary interface between the customer, the testing team and the leadership team for smooth communication.
• Understand the test vehicle requirements/ CTQs, existing lab/ facility capabilities & collaborate with the customers to firm up the design requirements. Make the technical proposals accordingly and pitch in with the Customer/ stakeholders.
• Review the test rig upgrades & own the design reviews/ action items. Track/promote assigned AIs & DRs in electronic reporting/tracking systems (PLM).
• Provide technical oversight to team and conduct the critical reviews of test hardware design.
• Deliver technical presentations at design reviews & program reviews (safety reviews, red flag reviews, and similar). Track/close AIs in PLM.
• Actively engage in test planning across internal functions and external functions (e.g. Customer, SFO, Design Team, vendors, and similar).
• Prepare/review test rig build & teardown documentation including: Build Books, clearances, thrust, alignment, & other inspections documentation.
• Provide technical guidance & work planning direction to a team of 4-6 test engineers/specialists. Provide technical guidance to crafts resources supporting teardown/build activities.
• Review the technical drawings and ensure that these drawing meet the design intent. To work closely with manufacturers suppliers to get the right material/ manufacturing as per the requirements. To check on the incoming raw material, inspection reports, NDT reports at various stages of manufacturing and act on the deviations/ misses accordingly.
• To perform RCA and identify possible reasons for discrepancies/ abnormalities. To provide quick fixes to enable the tests.
• Provide feedback to individuals and provide objective-based performance input during the team appraisals.
• Mentor/develop junior TE/FE in designing/ testing aspects.
• Problem solving mindset, should take quick decisions to enable high say/do ratio without compromising on safety. Should talk to SMEs to enable these solutions with quick turnaround times.
• To look for new areas of expansion, work closely with PL to enable testing's in new areas of expansion.
• Maintain ISO compliance.

Required Qualifications

• BS/MS degree in Mechanical/ Aerospace Engineering or related technical discipline from reputed university.
• Minimum of 10+ years experience in design and analysis, especially focusing on rotating equipment and/or structures/component design, turbine/compressor/rotor engineering, power plant knowledge, fluid-structure interactions, industrial machine manufacturing, instrumentation and/or multi deciplanary laboratory testing skills.
• Working experience with design and analysis tools including ANSYS Classic, ANSYS WB, Unigraphics, other structural/ fluid analysis software.
• Cognizant with ASME and other codes and standards
• Familiar with PLM and standard NPI or equivalent processes
• Working experience on making proposals, uncertainty analysis,
• Experience with Lean and Six Sigma tools and processes.
• GB certified (GE employees only).
• Knowledge on GDT, manufacturing aspects (welding, machining), NDT procedures

Desired Characteristics

• Experience in steam turbine technology, gas turbine technology, mechanical, performance, high temperature and pressure, and/or other laboratory testing.
• Knowledge of pressure vessel design, test methodologies, Instrumentation routing methods/ technics, test instrumentation and measurement systems, power plant and process equipment, data acquisition system and data processing.
• Knowledge in SAFER, HazOp, Design Reviews, Red Flag Reviews, Test Record Files, Data system equipment.
• Strong technical communication (verbal and written).
• Ability to lead and mentor Test/Facility Engineers & Test Specialists.
• Commitment to customer, teamwork and for team success.